Modular Storage Assemblies and Components Thereof

ABSTRACT

A pole cup for a hang rod may include a wall-mountable member, and a cradle extending from the wall-mountable member. The cradle may include a substantially u-shaped sidewall defining a cavity for securely receiving an end of the hang rod such that the hang rod is retained in a downward first direction, in a lateral second direction, and in a lateral third direction opposed to the second direction, when the hang rod is positioned within the cavity. A pair of ribs extend from a cavity-facing surface of the substantially u-shaped sidewall. A modular storage assembly may include a hang rod and a pole cup. A method of installing a modular storage assembly may include mounting to a wall at least one bracket configured to support a shelf, installing trim for the shelf, and mounting a pole cup to a wall via the wall-mountable member.

FIELD OF THE DISCLOSURE

This disclosure generally relates to modular storage assemblies, such asmodular closet assemblies, and specifically relates to components ofmodular storage assemblies, such as pole cups.

BACKGROUND

Modular storage systems are known that provide for flexible andefficient storage of items in residential, workplace, and industrialsettings. For example, such storage systems may optionally include acombination of shelves, drawers, hang rods, and other components toprovide various storage options for goods such as clothes, accessories,shoes, linens, containers, and the like. Different sizes and shapes ofshelves and drawers, different attachment and mounting mechanisms, anddifferent storage components (e.g., wire baskets, shoe-stands, tie/beltracks, hang rods) may be configured in various combinations to provide acustomizable storage assembly for any storage area (e.g., closet, shed,pantry, utility room, locker).

Often, consumers install the components of a customizable storageassembly themselves and therefore ease and simplicity of installation,modification, and removal is critical. Thus, modular storage assembliesand components that facilitate easy installation, modification, andremoval are desirable.

SUMMARY

Pole cups, modular storage assemblies including pole cups, and methodsof installing modular storage assemblies are described.

In embodiments, a pole cup for a hang rod includes a wall-mountablemember, and a cradle extending from the wall-mountable member. Thecradle may include a substantially u-shaped sidewall defining a cavityfor securely receiving an end of the hang rod such that the hang rod isretained in a downward first direction, in a lateral second direction,and in a lateral third direction opposed to the second direction, whenthe hang rod is positioned within the cavity. A pair of ribs may extendfrom a cavity-facing surface of the substantially u-shaped sidewall. Thepair of ribs may be configured to retain the hang rod in an upwardfourth direction opposed to the first direction, when the hang rod ispositioned within the cavity. The ribs may be sized and shaped to allowfor the end of the hang rod to be snap fit into the cavity.

In embodiments, a modular storage assembly may include a hang rod and apole cup.

In embodiments, a modular storage assembly may include a shelf, awall-mounted bracket configured to support the shelf, a trim incommunication with an end of the shelf, and a pole cup of claim 1. Thetrim may include a visual indication of an installation position for thepole cup.

In embodiments, a method of installing a modular storage assemblyincludes mounting to a wall at least one bracket configured to support ashelf, installing trim for the shelf, and mounting a pole cup to a wallvia the wall-mountable member. The pole cup is mountable subsequent toinstallation of the trim.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description is set forth with reference to the accompanyingdrawings. The use of the same reference numerals may indicate similar toidentical items. Various embodiments may utilize elements and/orcomponents other than those illustrated in the drawings, and someelements and/or components may not be present in various embodiments.Elements and/or components in the figures are not necessarily drawn toscale.

FIG. 1 is a perspective view of one embodiment of a modular storageassembly, as described herein.

FIG. 2A is a perspective view of one embodiment of a pole cup for amodular storage assembly, as described herein.

FIG. 2B is a front view of the pole cup of FIG. 2A.

FIG. 2C is a rear view of the pole cup of FIG. 2A.

FIG. 2D is a side view of the pole cup of FIG. 2A.

FIG. 2E is an upper view of the pole cup of FIG. 2A.

FIG. 3A is a perspective view of one embodiment of a pole cup for amodular storage assembly, as described herein.

FIG. 3B is a front view of the pole cup of FIG. 3A.

FIG. 3C is a cross-sectional view of the pole cup of FIG. 3A.

FIG. 3D is a side view of the pole cup of FIG. 3A.

FIG. 3E is a rear view of the pole cup of FIG. 3A.

DETAILED DESCRIPTION

The present disclosure includes non-limiting embodiments of modularstorage assemblies, components thereof, and methods for installing suchassemblies and components. The embodiments are described in detailherein to enable one of ordinary skill in the art to practice themodular assembles, components and associated methods of making, althoughit is to be understood that other embodiments may be utilized and thatlogical changes may be made without departing from the scope of thedisclosure. Throughout the disclosure, depending on the context,singular and plural terminology may be used interchangeably.

Modular storage assemblies and systems (terms used interchangeablyherein), and components thereof, are described herein. In particular, apole cup for securely retaining a hang rod within a modular storageassembly has been developed. Methods of installing such assemblies arealso described. These storage assemblies may be any suitableconfiguration of components for storing items in residential, workplace,and industrial settings (e.g., in closets, sheds, utility rooms,pantries, and lockers). For example, the storage assemblies may includecombinations of shelves, drawers, hang rods, attachment and mountingmechanisms, and storage components (e.g., shoe-stands, tie/belt racks).A user may design a particular storage assembly utilizing any suitablecombination of components or a kit of components may be provided thatincludes the components for a pre-designed assembly. Beneficially, suchstorage assemblies and components may be combined in various operableconfigurations, to suit the desired storage needs and available spacefor the installation. Because these systems may be installed without thehelp of professional installers, ease of installation, removal, andreconfiguration or modification of the components is important.

One embodiment of such a modular storage assembly is shown in FIG. 1.Here, the assembly 100 includes a pole cup 200 for securely receivingand retaining one end of a hang rod 300. Additionally, the assembly 100includes a wall bracket 400, which supports a shelf 500, with the shelfhaving a trim 600. This particular assembly configuration is used forexemplary purposes only, and it should be understood that anyconfiguration of modular storage assembly and components is intended tobe encompassed by the disclosure.

Various embodiments of pole cups, storage assemblies, and methods ofinstalling the assemblies are described below.

Pole Cups

In certain embodiments, a pole cup for a hang rod is provided. The polecup may be effective at securing an end of the hang rod at a wall orsimilar structure. In certain embodiments, a pair of pole cups is usedto secure the opposed ends of a hang rod. FIG. 1 illustrates a pole cup200 mounted on a wall and securing an end of hang rod 300. In otherembodiments, one end of the hang rod is secured in the pole cup whilethe other end is secured by another component of the modular assembly,such as by a pole cup type structure positioned within the assembly(e.g., on a wall-mounted bracket or other component disposed at anintermediate position along the length of the assembly).

In one aspect, a pole cup for a hang rod includes a wall-mountablemember, and a cradle extending from the wall-mountable member, thecradle having a substantially u-shaped sidewall defining a cavity forsecurely receiving an end of the hang rod such that the hang rod isretained in a downward first direction, in a lateral second direction,and in a lateral third direction opposed to the second direction, whenthe hang rod is positioned within the cavity, wherein a pair of ribsextend from a cavity-facing surface of the substantially u-shapedsidewall, the pair of ribs being configured to retain the hang rod in anupward fourth direction opposed to the first direction, when the hangrod is positioned within the cavity, and wherein the ribs are sized andshaped to allow for the end of the hang rod to be tightly fit (e.g.,snap, friction, or interference fit) into the cavity.

Various embodiments of such pole cups are illustrated in FIGS. 2 and 3.As shown in FIG. 2A, pole cup 200 includes a wall-mountable member 202and a cradle 204 extending from the wall-mountable member 202. Thewall-mountable member 202 may have any suitable configuration, size, andshape that is effective to allow for secure mounting of the pole cup 200to a wall or similar structure with sufficient structural integrity tosupport a hang rod and contents stored thereon (e.g., hanging clothes).For example, the pole cup and hang rod may be configured to support 25pounds or more, such as 40 pounds or more, 50 pounds or more, 75 poundsor more, 100 pounds or more, 150 pounds or more, or 200 pounds or more,depending on the length and material of construction of the hang rod andthe design of the pole cup.

For example, the wall-mountable member 202 may be generally planar inoverall shape, with one or more apertures 212 therethrough for receivinga fastener for wall-mounting. As shown in FIG. 2A, in certainembodiments, the wall-mountable member 202 has two or more apertures 212therethrough. For example, the apertures 212 may be configured toaccommodate mechanical fasteners (e.g., screws, nails) to mount the polecup 200 to a wall. As shown in FIG. 2C, the wall-mountable member 202may include reinforcing ribs 213 to provide increased structural supporton a rear surface of the member 202. Additionally, the front surface ofthe member 202 may include a tapered or blunt edge.

As shown in FIG. 2A, the pole cup 200 also includes a cradle 204extending from the wall-mountable member 202. The cradle 204 isconfigured to receive an end of a hang rod and secure the end therein.In certain embodiments, as shown in FIG. 2A, the cradle 204 includes asubstantially u-shaped sidewall 206 that defines a cavity 208 in whichthe end of the hang rod is securely received. As used herein, the phrase“u-shaped sidewall” is used to refer to a single wall or a series ofwalls that extend from a front surface of the wall-mountable member asuitable length to retain an end of the hand rod therein during regularuse (e.g., about 0.5 inch, about 0.75 inch, about 1 inch). In someembodiments, as shown in FIG. 2A, the u-shaped sidewall 206 has avariable depth, with each end of the sidewall 206 having a taperedprofile. As used herein, the term “about” is used to encompass a rangeof ±5 percent of the numerical value it is used to define.

For example, the u-shaped sidewall may have an inner surface (i.e.,cavity-facing surface) that is substantially u-shaped, while the opposedouter surface may have any suitable shape (e.g., may also be u-shaped asillustrated in the Figures, or may be rectangular, ridged, or otherwiseshaped). As shown in FIG. 2B, the u-shaped sidewall 206 is configuredsuch that a hang rod installed therein is retained in a downward firstdirection A, in a lateral second direction B, and in a lateral thirddirection C opposed to the second direction B, when the hang rod ispositioned within the cavity.

In certain embodiments, as shown in FIGS. 2A and 2B, the cradle 204includes a pair of ribs 210 extending from the inner surface of thesubstantially u-shaped sidewall 206. The ribs 210 are configured toretain the hang rod in an upward fourth direction D opposed to the firstdirection A, when the hang rod is positioned within the cavity. That is,the ribs may be configured to retain the hang rod in the cavity underregular use conditions (e.g., absent an atypical upward force on thehang rod). The directions A, B, C, D, as illustrated in FIG. 2B, arereferred to herein as downward, lateral, and upward directions for easeof illustration. Such directions are relevant to the pole cup installedin a regular position (i.e., with the opening to the cavity facingupward); however, it should be understood that alternative installationconfigurations and alternative configurations of the sidewall arepossible to achieve the desired hang rod retention.

The ribs 210 are sized and shaped to allow for the end of the hang rodto be snap fit into the cavity 208. For example, the ribs 210 may beformed in any suitable shape, such as an elongated, substantially linearshape, as shown in the FIGS. For example, the ribs may have a curved,blunt, pointed, or tapered surface profile. The ribs 210 may extend fromthe inner surface of the sidewall 206 along at least a portion of thedepth, or length, thereof. For example, the ribs 210 may extendlongitudinally across at least 50 percent of the depth, at least 75percent of the depth, at least 95 percent of the depth, or at least 99percent of the depth of the sidewall 206. Generally, the ribs 210 extendalong the sidewall 206 in a direction substantially perpendicular to theplane of the wall-mountable member 202.

In some embodiments, as shown in FIG. 2, the u-shaped sidewall 206 isformed by an upper portion and a lower portion, which are divided by theribs 210. For example, the inner-surface of the lower portion issemi-circular, and configured to retain snugly the end of a round hangrod therein. That is, the semi-circular lower portion may have a radiusthat is essentially the same as the radius of the outer surface of thehang rod. For example, the upper portion of the sidewall 206 may includesubstantially linear wall portions extending upwardly from the ends ofthe semi-circular lower portion. These substantially linear wallportions may be angled slightly outward to provide a funnel opening inwhich a user can more easily introduce the end of the hang rod into thecavity. These substantially linear wall portions may have the same depthas the lower portion, or may have a decreasing depth from the edge ofthe lower portion. That is, as shown in FIG. 2D, the depth of thesidewall 206 may decrease along the upper portion. In certainembodiments, as shown in FIG. 2B, the surface profile of the ribs 210may be continuous with the surface of the semi-circular lower portion ofthe sidewall 206, such that the surface of the ribs 210 continues thearc of the semi-circular portion.

In certain embodiments, the cavity-facing inner surface of thesubstantially u-shaped sidewall 206 is substantially smooth other thanthe pair of ribs 210. That is, the pair of ribs 210 may be the solesurface feature disposed on the otherwise smooth inner surface of thesidewall 206. In certain embodiments, the substantially u-shapedsidewall 206 does not contain any aperture extending therethrough. Thatis, the pole cup does not require any mechanical fastener to retain thehang rod in the cavity. Instead, the pole cup retains the hang rod inthe cavity in the absence of any additional hardware or fastenerconnecting the hang rod to the pole cup. Beneficially, this designrequires no hardware or modifications to a hang rod (e.g., an aperturefor receiving a fastener) to install the hang rod in the pole cup, whileachieving an effective snap fit that retains the hang rod in the cavityin all directions. Moreover, a hang rod can be installed in thepresently described pole cups in any orientation, without the need forrotating the rod to align with a fastener mechanism.

The pole cup may be formed of suitable materials such as metals, metalalloys, and plastics. For example, the pole cup may be formed of analuminum alloy.

One embodiment of a pole cup 250 is illustrated in FIGS. 3A-3E, withdimensions provided in inches [mm]. This pole cup may have the featuresdescribed above with reference to FIG. 2.

Modular Assemblies

Modular storage assemblies are also provided herein. As described above,these assemblies generally may include any combination of components asdesired for the particular storage capacity of the assembly and asappropriate for the floorplan and volume of the storage area.

In certain embodiments, a modular storage assembly includes a pole cupand a hang rod. For example, the pole cup may be any suitable embodimentof pole cup described herein. The hang rod may be any suitabledimensions and construction to be installed within the storage assemblyand provide the desired storage capacity (e.g., for hanging clothes,shoe/tie/belt racks, other storage containers).

For example, the hang rod may have a round cross-sectional shape with asuitable diameter to allow an end of the hang rod to be positionedwithin the cavity of the pole cup. In certain embodiments, the hang rodhas a diameter of from about 0.5 inches to about 2 inches. For example,the diameter of the hang rod may be about 1 inch, about 1.25 inches,about 1.5 inches, or about 1.75 inches. In certain embodiments, thecavity has a diameter measured across the substantially u-shapedsidewall that is about the diameter of the hang rod, to accommodate thehang rod snugly therein. In certain embodiments, the hang rod has alength of from about 1 foot to about 12 feet. For example, the length ofthe hang rod may be from about 2 to about 10 feet, such as about 3 feet,about 4 feet, about 5 feet, about 6 feet, about 8 feet, about 10 feet,or any length therebetween.

As discussed above with reference, in certain embodiments thewall-mountable member has at least one aperture extending therethrough.In such embodiments, the assembly includes at least one fastenerconfigured to be positioned in the aperture to mount the pole cup to awall. For example, the at least one fastener may be a screw or nail.

In certain embodiments, as shown in FIG. 1, a modular storage assembly100 includes one or more of the following components: a shelf 500, atleast one wall-mounted bracket 400 configured to support the shelf 500,a trim 600 in communication with an end of the shelf 500, a pole cup200, and a hang rod 300.

Any suitable types of these components may be employed in the assembly.For example, the shelf 500 may be any suitable plank or other styleshelf. The wall-mounted bracket 400 may be any suitable L-bracket,reinforced L-bracket, or other bracket type that is configured forsecure mounting to a wall or similar structure. The wall-mountedbracket(s) 400 should be suitable to support a shelf, as well as thegoods to be stored thereon.

The trim 600 may be a decorative component, similar to a baseboard orcrown molding, which is positioned at the end of a shelf 500 and trimsthe edges of the shelf 500. In certain embodiments, the assembly 100 isconfigured such that the pole cup 200 is installed adjacent or near thetrim 600. In such embodiments, the trim 600 may include a visualindication of an installation position for the pole cup. That is, thevisual indication on the trim 600 may show a user the preferredinstallation position of the pole cup. For example, the visualindication may be an indentation, a bump or other raised feature, orsimply a marking on the surface of the trim. In some embodiments, thevisual indication is a molded indentation in the trim 600.

Methods of Installation

Methods of installing the modular storage assemblies and componentsdescribed herein are also provided. The methods may include installingany embodiments of the assemblies and components that have beendescribed herein.

In certain embodiments, a method of installing a modular storageassembly includes mounting to a wall at least one bracket configured tosupport a shelf, installing trim for the shelf, and mounting a pole cupto a wall via the wall-mountable member, wherein the pole cup ismountable subsequent to installation of the trim. As described above,the bracket may have any suitable bracket design, and may be configuredto be mounted to a wall via one or more suitable fasteners (e.g.,screws, nails). The trim may be installed separately from or inconjunction with installation of the shelf on the bracket. Beneficially,the pole cup may be installed prior to or after installation of thebracket, trim and/or shelf. In particular, the pole cup may be mountedto a wall, via the wall-mountable member, after installation of theshelf and/or trim. In certain embodiments, the method further includesinstalling a hang rod by positioning an end of the hang rod in thecradle of the pole cup and securing it therein. The second end of thehang rod may be positioned in a second opposed pole cup or in anothersuitable cradle of the assembly, as discussed above.

This configuration provides a benefit of flexibility of installation,such that the pole cup and hang rod can be installed separate from andafter installation of the shelf, which allows users to later modifytheir assembly to include a hang rod, without requiring removal of someor all of the shelf, trim, and bracket, to accommodate installation ofthe pole cup. In known storage assemblies, the pole cup and othercomponents are often configured such that the pole cup must be installedprior to the installation of the brackets, shelf, or trim, and thereforesaid additional components must be disassembled to accommodate any lateraddition of a hang rod to the assembly.

In certain embodiments, as discussed above, the trim may be installedprior to installation of the pole cup and may include a visualindication of an installation position for the pole cup thereon, tofacilitate proper placement and installation of the pole cup by theuser.

As can be seen in FIG. 1, in a typical assembly 100 configuration, thepole cup 200 may be mounted to a wall that is substantiallyperpendicular to the wall on which the bracket 400 is mounted.

Beneficially, the pole cup design described herein provides for flexibleinstallation of the pole cup throughout the assembly installationprocess, and allows for secure installation and retention of a hang rodtherein, via the u-shaped design and ribs. In contrast to known polecups, the present design does not require additional hardware or aparticular orientation of the hang rod for securement within the polecup. Additionally, the open cavity design of the u-shaped sidewallallows for easy introduction and removal of an end of the hang rod intothe cavity, which feature full circular pole cup designs lack.

While the disclosure has been described with reference to a number ofembodiments, it will be understood by those skilled in the art that thedisclosure is not limited to such disclosed embodiments. Rather, thedisclosure can be modified to incorporate any number of variations,alterations, substitutions, or equivalent arrangements not describedherein, but which are commensurate with the spirit and scope of thedisclosure. Conditional language used herein, such as “can,” “could,”“might,” or “may,” unless specifically stated otherwise, or otherwiseunderstood within the context as used, generally is intended to conveythat certain embodiments include, while other embodiments do notinclude, certain features, elements or functional capabilities.Additionally, while various embodiments of the disclosure have beendescribed, it is to be understood that aspects of the disclosure mayinclude only some of the described embodiments. Accordingly, thedisclosure is not to be seen as limited by the foregoing description,but is only limited by the scope of the appended claims.

What is claimed is:
 1. A pole cup for a hang rod, comprising: awall-mountable member; and a cradle extending from the wall-mountablemember, the cradle comprising a substantially u-shaped sidewall defininga cavity for securely receiving an end of the hang rod such that thehang rod is retained in a downward first direction, in a lateral seconddirection, and in a lateral third direction opposed to the seconddirection, when the hang rod is positioned within the cavity, wherein apair of ribs extend from a cavity-facing surface of the substantiallyu-shaped sidewall, the pair of ribs being configured to retain the hangrod in an upward fourth direction opposed to the first direction, whenthe hang rod is positioned within the cavity, and wherein the ribs aresized and shaped to allow for the end of the hang rod to be snap fitinto the cavity.
 2. The pole cup of claim 1, wherein the wall-mountablemember is substantially planar.
 3. The pole cup of claim 1, wherein thewall-mountable member comprises at least one aperture extendingtherethrough for accommodating a fastener to mount the pole cup to awall.
 4. The pole cup of claim 1, wherein the cavity-facing surface ofthe substantially u-shaped sidewall is substantially smooth other thanthe pair of ribs.
 5. The pole cup of claim 1, wherein the substantiallyu-shaped sidewall does not contain any aperture extending therethrough.6. The pole cup of claim 1, wherein the pole cup is formed of aluminum.7. A modular storage assembly, comprising: a hang rod; and the pole cupof claim
 1. 8. The modular storage assembly of claim 7, wherein: thehang rod has a cross-sectional diameter, and the cavity has a diametermeasured across the substantially u-shaped sidewall, the diameter of thecavity being substantially equal to the diameter of the hang rod.
 9. Themodular storage assembly of claim 8, wherein the diameter of the hangrod is 1 inch, 1.25 inches, 1.5 inches, or 1.75 inches.
 10. The modularstorage assembly of claim 7, wherein: the wall-mountable membercomprises at least one aperture extending therethrough, and the assemblyfurther comprises at least one fastener configured to be positioned inthe aperture to mount the pole cup to a wall.
 11. The modular storageassembly of claim 10, wherein the at least one fastener is a screw ornail.
 12. A modular storage assembly, comprising: a shelf; awall-mounted bracket configured to support the shelf; a trim incommunication with an end of the shelf; and the pole cup of claim 1,wherein the trim comprises a visual indication of an installationposition for the pole cup.
 13. The modular storage assembly of claim 12,wherein the visual indication is molded in the trim.
 14. A method ofinstalling a modular storage assembly, comprising: mounting to a wall atleast one bracket configured to support a shelf; installing trim for theshelf; and mounting the pole cup of claim 1 to a wall via thewall-mountable member, wherein the pole cup is mountable subsequent toinstallation of the trim.
 15. The method of claim 14, wherein the trimcomprises a visual indication of an installation position for the polecup.
 16. The method of claim 15, wherein the visual indication is moldedin the trim.
 17. The method of claim 14, further comprising installing ashelf on the at least one bracket and in communication with the trim.18. The method of claim 14, further comprising installing a hang rod bypositioning an end of the hang rod in the cradle.